Research Papers

Grinding Energy Modeling Based on Friction, Plowing, and Shearing

[+] Author and Article Information
Barbara S. Linke

Mechanical and Aerospace
Engineering Department,
University of California Davis,
1 Shields Avenue,
Davis, CA 95616
e-mail: bslinke@ucdavis.edu

Ian Garretson

Mechanical and Aerospace
Engineering Department,
University of California Davis,
1 Shields Avenue,
Davis, CA 95616
e-mail: icgarretson@ucdavis.edu

Francois Torner

Department of Mechanical and Process
Institute for Measurement
and Sensor-Technology,
University of Kaiserslautern,
Kaiserslautern 67663, Germany
e-mail: torner@mv.uni-kl.de

Joerg Seewig

Department of Mechanical and Process
Institute for Measurement
and Sensor-Technology,
University of Kaiserslautern,
Kaiserslautern 67663, Germany
e-mail: seewig@mv.uni-kl.de

Manuscript received March 30, 2017; final manuscript received June 15, 2017; published online November 2, 2017. Assoc. Editor: Mark Jackson.

J. Manuf. Sci. Eng 139(12), 121009 (Nov 02, 2017) (11 pages) Paper No: MANU-17-1191; doi: 10.1115/1.4037239 History: Received March 30, 2017; Revised June 15, 2017

Grinding is an important abrasive machining process at the end of many process chains. Understanding energy transformation in grinding is not only important to improve energy efficiency but also crucial for understanding the chip formation process itself. Grinding energy can be studied at the macroscopic or microscopic levels, wherein the entire grinding tool is considered or the phenomena at the single cutting edges are studied. This paper explores existing energy modeling approaches in grinding with particular emphasis on physical models. Models on energy transformation during the ductile grit–workpiece engagement for three regimes —being friction, plowing, and shearing —are explained. In addition to the critical depth of cut (DOC) when chip formation starts, a critical depth when plowing begins is introduced to divide between the different regimes. Selected models for each regime are combined to an integrated grinding energy model that allows researchers to investigate forces and energy during grit engagement.

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Fig. 1

Chip length and undeformed chip thickness for different grinding kinematics with example parameters

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Fig. 2

Left: Wheel engagement in surface grinding, Right: Grit engagement zones (after Refs. [4] and [12])

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Fig. 4

Groove cross section and bulges from plowing

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Fig. 5

Three engagement cases depending on maximum grit depth of cut

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Fig. 6

Chip geometry after Refs. [11] and [17] with grit width bcu

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Fig. 8

Energy model overview; shaded boxes shows reoccurring chip geometry values

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Fig. 9

Forces for the engagement of one cutting edge, setting A from Table 2

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Fig. 10

Energies for the engagement of one cutting edge, setting A from Table 2

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Fig. 11

Comparison of the six settings with respect to specific energy, forces, and maximum energy per cutting edge




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